Shipping container having a controllably stretchable liner

ABSTRACT

A shipping container comprising a rigid outer container and an inner flexible liner assembly. The rigid outer container defines a cavity. The inner flexible liner assembly is in the cavity and includes a liner and a spout. The liner has a plurality of walls defining an inner cavity, and, the walls including a spout surrounding region. The spout is positioned such that the spout surrounding region extends thereabout. The spout provides fluid communication with the inner cavity of the liner. The spout includes a one way valve which facilitates the ingress of flowable material while precluding the egress of material. Upon filling of the liner with a flowable material, the spout surrounding region is structurally configured for controllable stretching to accommodate the flowable material. A liner for use in a shipping container as well as a method of filling such a liner is disclosed.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates in general to shipping containers having a rigid outer container and a flexible bag positioned therein, and more particularly, to a shipping container which includes a controllably stretchable inner liner which enhances the durability and integrity of the shipping container.

2. Background Art

The use of flexible bags for the transport of various materials is known in the art. In particular, such flexible bags can be filled with any number of different flowable materials for later dispensing or emptying. In certain applications, such flexible bags may be on the order of 400 liters, or larger (i.e., 4000 liters). Often, such larger containers are positioned within a rigid outer container so as to provide a stable skeleton for retaining and managing the flexible bag.

In many such configurations, the inner flexible bag performs a liner function. For example, a large rigid container may be provided. An inner liner can be positioned within the outer liner and filled with a flowable material. Upon the emptying of the inner flexible bag, the bag can be discarded. In turn, it is not necessary to clean or otherwise configure the outer rigid container to retain the flowable material, as the material never touches the outer rigid container.

While such configurations have proven to be quite useful, there have been drawbacks. In particular, the liners associated with the rigid outer containers can be compromised during the shipment threreof. Stress fractures may occur in the liner material due to the constant shifting of the flowable material during transport. These fractures can lead to outright leaks which can destroy the flowable material, the outer rigid container, or at the very least cause an undesirable condition.

Certain enhancements have been made to the materials from which the inner liners are formed. The materials have been enhanced so as to resist stress fractures that lead to pinhole leaks. In addition, the size and shape of the inner bag has been altered in many embodiments, so as to reduce the chances that the container is moved by the flowable material. While such enhancements have created improved integrity for the configuration, there have nevertheless been problems.

Amongst other problems, the alternative liner constructions comprise more complex materials and techniques, which increases the cost of the overall packaging. Furthermore, certain liner constructions have only marginally enhanced the operation of the resulting embodiment.

It is an object of the present invention to provide an improved shipping container utilizing in combination a rigid outer container combined with a flexible inner bag or liner.

It is another object of the present invention to provide a shipping container which includes a liner that minimizes the possibility of the fracture or breach of the inner liner, and, therefore contamination of the flowable material positioned therein.

It is another object of the invention to provide a flexible inner bag or liner which can stretch controllably when filled with a flowable material so as to minimize the failure of the inner bag or liner.

These objects as well as other objects of the present invention will become apparent in light of the present specification, claims, and drawings.

SUMMARY OF THE INVENTION

In a first aspect of the invention, the invention is directed to a shipping container comprising a rigid outer container and an inner flexible liner assembly. The rigid outer container defines a cavity. The inner flexible liner assembly is in the cavity and includes a liner and a spout. The liner has a plurality of walls defining an inner cavity, and, the walls including a spout surrounding region. The spout is positioned such that the spout surrounding region extends thereabout. The spout provides fluid communication with the inner cavity of the liner. The spout includes a one way valve which facilitates the ingress of flowable material while precluding the egress of material. Upon filling of the liner with a flowable material, the spout surrounding region is structurally configured for controllable stretching to accommodate the flowable material.

In one such embodiment, the walls of the liner further include a sidewall abutting region extending from the spout surrounding region and a base abutting region extending from the sidewall abutting region. The sidewall abutting region corresponds to the sidewalls of the rigid outer container. The base abutting region corresponds to the base of the rigid outer container.

In a preferred embodiment, the spout further includes a base flange which is secured to the liner, the one way valve member includes a material flap which is attached to the spout by way of a weld. A portion of the material flap is positionable in abutment with a lower surface of the base flange, to, in turn, seal the spout from egress of flowable material.

In another preferred embodiment, the spout surrounding region is structurally configured for stretching between 5% and 15% in any direction.

In a preferred embodiment, the spout surrounding region is substantially free of each of creases and folds upon the stretching thereof.

In another aspect of the invention, the invention comprises a liner assembly for a shipping container, wherein the liner is positionable within an outer rigid container and fillable with a flowable material. The liner assembly comprises a liner and a spout. The liner has a plurality of walls defining an inner cavity. The walls including a spout surrounding region. The spout is positioned such that the spout surrounding region extends thereabout. The spout provides fluid communication with the inner cavity of the liner. The spout includes a one way valve which facilitates the ingress of flowable material while precluding the egress of material. Upon filling of the liner with a flowable material, the spout surrounding region is structurally configured for controllable stretching to accommodate the flowable material.

In a preferred embodiment, the spout further includes a base flange which is secured to the liner, the one way valve member includes a material flap which is attached to the spout by way of a weld. A portion of the material flap is positionable in abutment with a lower surface of the base flange, to, in turn, seal the spout from egress of flowable material.

In another embodiment, the spout surrounding region is structurally configured for stretching between 5% and 15% in any direction.

In another embodiment, the spout surrounding region is substantially free of each of creases and folds upon the stretching thereof.

In yet another embodiment, the liner assembly further includes means for controlling the stretching of at least one sub-region of the spout surrounding region.

In yet another aspect of the invention, the invention comprises a method of filling a shipping container comprising: providing a rigid outer container; placing a flexible liner assembly within a cavity defined by the rigid outer container, the liner including walls defining a spout surrounding region and a spout; filling the flexible liner with a flowable material through the spout; and stretching the spout surrounding region with the flowable material during filling.

In one embodiment of the method, the method includes the step of precluding the egress of flowable material through the spout at least during the step of stretching the spout surrounding region.

In another embodiment, the method includes the step of precluding the stretching of any regions other than the spout surrounding region of the liner.

Preferably, the step of stretching further comprises the step of stretching the spout surrounding region until the spout surrounding region is substantially free from creases and folds.

In another embodiment, the step of stretching further comprises the step of stretching the spout surrounding region between 5% and 15% in at least one direction.

In yet another embodiment, the step of stretching increases a volume of the liner by at least 5%.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described with reference to the drawings wherein:

FIG. 1 of the drawings is a perspective view of an embodiment of the shipping container of the present invention;

FIG. 2 of the drawings is a cross-sectional view of an embodiment of the shipping container of the present invention, showing, in particular, the filling thereof;

FIG. 3 of the drawings is a cross-sectional view of an embodiment of the shipping container of the present invention, showing, in particular, the stretching of the spout surrounding region by the flowable material;

FIG. 4 of the drawings is a top plan view of an embodiment of the shipping container of the present invention after filling thereof; and

FIG. 5 of the drawings is a side elevational view of an embodiment of the spout of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and described herein in detail a specific embodiment with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiment illustrated.

It will be understood that like or analogous elements and/or components, referred to herein, may be identified throughout the drawings by like reference characters. In addition, it will be understood that the drawings are merely schematic representations of the invention, and some of the components may have been distorted from actual scale for purposes of pictorial clarity.

Referring now to the drawings and in particular to FIG. 1, shipping container is shown generally at 10. The shipping container includes outer rigid container 12 and inner flexible container 14. The inner flexible container is positioned within the outer rigid container, so as to, in turn, form a liner for the outer rigid container. With reference to FIG. 2, the inner flexible liner is filled with a flowable material 110 which is supplied by a filler 100.

Flowable material may comprise any number of different materials which can be filled into the container of the present invention, preferably from a filler head. Such materials include liquids, gels, pastes, syrups, as well as such materials which additionally include solids suspended therein.

Outer rigid container 12 includes base 20, side walls, such as sidewall 22 and upper opening 24. The base often may include provisions by which the outer rigid container can be handled, moved and transported. In the embodiment shown, the base 20 includes an integrated or separate pallet configuration. As such, the outer rigid container can be handled by a forklift or the like.

Sidewalls 22 comprise a plurality of walls extending from the base 20 in a generally upward direction. The sidewalls may provide a cubic configuration to the rigid container, while other configurations are contemplated. In the particular embodiment shown, the sidewalls along with the base define a square cubic configuration, having cavity 23. The sidewalls 22 and a portion of the base 20 may comprise a corrugated paperboard material. In other embodiments, the sidewalls and the base may comprise a polymer material or a wooden material. Of course, other materials are contemplated, as well as combinations of the foregoing materials.

Upper opening 24 may include a cover which is integrated with one or more of the sidewalls. The upper opening 24 provides ingress and egress from the cavity 23. In other embodiments, the cover may be omitted and the cavity 23 can be exposed at all times to the outside conditions. In other embodiments, the cover may extend over the outside or inside of portions of the sidewalls. Additional structures, such as straps, clips, pins, etc may be utilized so as to retain the cover in a desired position relative to the upper opening 24.

Inner flexible assembly 14 is shown in FIG. 1 as comprising liner 30 and spout 32. The liner 30 includes walls 34 which serve to define a flowable material retaining cavity 53 (FIG. 2). The walls 34 may comprise any number of different polymer based materials in any one of a monolithic, laminated or coextruded configuration. Such materials may have metallic or other non-polymer coating applied to certain surfaces thereof. Typically such a liner is formed from a plurality of walls which are joined together at seals to form the cavity 53. Cavity 53 is typically fluid tight. Additionally, the walls may comprise a single ply or may comprise multiple plies of material which are joined at various places, such as seals.

The walls 34 can be separated into a spout surrounding region 50, a sidewall abutting region 52 and a base abutting region 54. The walls typically can span multiple regions, and the various regions can overlap to some extent. The spout surrounding region comprises a region of the liner 30 which surrounds the spout 32. Typically, during shipment, only the outer fringes of this region contact the sidewalls of the outer rigid container. Sidewall abutting region 52 typically maintains contact with the sidewalls of the outer rigid container, and in certain circumstances the fringes of this region may contact the base or may be free from contact with the sidewalls during transport. Finally, the base abutting region 54 typically abuts the base of the outer rigid container. As with the other regions, the fringes of this region may contact the sidewalls during shipment and transport.

Spout surrounding region 50 includes means for facilitating the stretching of the liner. In particular, the spout surrounding region 50 is structurally configured so as to stretch by between five and fifteen percent. Such stretching can be achieved through the pressure of the flowable material 110 at the time of filling through the filler head 100. Typically, the stretching is preferably circumferentially uniform about spout 32. It will be understood that specific amount of stretch at any point radially extending from the spout can be varied. The spout surrounding region can be designed with specific sub-regions which controllably stretch in a desired sequence, to, in turn, provide means for controllably stretching sub-regions of the spout surrounding region. For example, the spout surrounding region can have a cone-shaped configuration which fosters the stretching of desirable sub-regions of the spout surrounding region as desired.

Preferably, the region of stretching results in stretching of regions of the spout surrounding region of between 5% and 15% in any one given direction. Of course, the invention is not limited to stretching in such ranges, or the stretching in any particular direction. Preferably, the stretching is such that the resulting spout surrounding region is substantially free of folds and creases.

Spout 32 is shown in FIG. 4 as comprising base flange 40, neck 42 and valve member 44. Base flange 40 is typically coupled to walls 34 of the liner 30. Typically, the liner 30 includes an opening, and, the base flange 40 is coupled to the walls 34 so as to surround the opening of the liner. Generally, the base flange is welded to the sidewalls through any one of heat, RF welding or the like.

As the base flange 40 is typically welded or otherwise attached to the inner surface of the liner, neck 42 extends through the opening in the liner and away therefrom. The neck provides fluid communication with the cavity 53 of liner 30. Any number of different closure systems may be employed so as to preclude fluid communication with the inner cavity. In certain embodiments, the spout may be threaded and a cap 63 (FIG. 5) having a mating threadform can be applied thereto. In other embodiments, a snap cap can be provided which covers the spout through an interference fit. In yet other embodiments, a tap or fitment may be provided which provides communication with the cavity on demand. Typically, the spout 32 comprises a polymer material.

With reference to FIGS. 4 and 5, a one way valve member 44 may be incorporated into the spout 32. Such a valve precludes the passage of material out of the cavity 53 upon filling of the cavity with flowable material. With reference to FIG. 5, the valve comprises material flap 60 which is attached to the spout by way of a weld 70. A portion 72 of the flap covers the opening defined by the neck 42 so as to preclude the passage of material from within the cavity, while permitting ingress into the cavity. In other embodiments, the valve may be coupled to other regions of the spout, or to portions of the liner

It will be understood that other valves and spouts may be incorporated into the liner 30. Such additional valves and spouts may be placed on any one of the sidewalls at any region. Typically, additional valves are preferably positioned away from the spout surrounding region 50. For example, a spout may be positioned on the liner proximate the interface between the sidewall abutting region 52 and the base abutting region 54. Such a position allows for the evacuation of fluid from within the cavity with the aid of gravity. Other positions are likewise contemplated.

In operation, the user is first provided with a rigid outer container. Once the rigid outer container is positioned as desired, the user can then insert the desired inner liner 30 into the cavity defined by the rigid outer container. Once properly inserted, the inner liner 30 can be filled with a flowable material. The invention is not limited to a particular flowable material, or a particular class of flowable materials.

Next, the spout 32 is associated with a filler head 100 and the flowable material is transferred to the liner 30. As the flowable material is filled, the liner begins to expand with the contents thereof. In particular, the base abutting region 54 approaches and contacts the base. Further filling expands the liner such that the sidewall abutting region 52 of the liner contacts and abuts the sidewalls 22 of the rigid outer liner. Finally, the liner approaches a filled condition.

Subsequently, further filling of the liner 30 serves to stretch a portion of the spout surrounding region 50 to accommodate the additional flowable material. Due to the stretching, the spout surrounding region becomes quite taut between the sidewalls toward the spout. Such a configuration is generally free of creases and folds in the spout surrounding region. The valve member 44 substantially precludes the egress of flowable material from within the cavity 53 during filling. The resulting volume of the overall liner may be increased by, for example 5% to 15%, although the invention is not limited to any particular amount of change in volume of the liner.

Once the desired amount of flowable material is introduced, and the spout surrounding region 50 has stretched to accommodate this flowable material, the filler head is stopped, thereby allowing no further flowable material into cavity 53. Egress of the flowable material is precluded by the material flap 60 of one way valve member 44. The filler head is then removed from within the cavity 53. The spout 32 is capped, closed or otherwise sealed. Finally, the container is ready for shipment.

Advantageously, inasmuch as the spout surrounding region has been stretched during the filling process, and desirably, at or near the conclusion of filling, the spout surrounding region is substantially free from folds, creases or other aberrations in the surface thereof. Furthermore, there is less head space within the cavity 53. In turn, during transport, the shifting of the contents has little detrimental effect to the liner. As a result, the integrity of the resulting shipping container can be greatly enhanced.

Moreover, due to the configuration of the spout surrounding region 50, the use of dunnage between the liner and the top of the rigid outer container is not required. The elimination of dunnage decreases cost, eliminates components and enhances the filling and dispensing and recycling of the container.

The foregoing description merely explains and illustrates the invention and the invention is not limited thereto except insofar as the appended claims are so limited, as those skilled in the art who have the disclosure before them will be able to make modifications without departing from the scope of the invention. 

1. A shipping container comprising: a rigid outer container having a base, a plurality of sidewalls and an upper opening configured to define a cavity; an inner flexible liner assembly positioned within the cavity of the rigid outer container comprising, a liner having a plurality of walls generally complementing the cavity of the rigid outer container, the liner defines an inner cavity, the walls of the liner include a spout surrounding region, a spout positioned such that the spout surrounding region extends thereabout, the spout providing fluid communication with the inner cavity of the liner, the spout including a one way valve which facilitates the ingress of flowable material while precluding the egress of material. whereupon filling of the liner with a flowable material, the spout surrounding region structurally configured for controllable stretching by the flowable material, to, in turn, facilitate flowable material in excess of a capacity of the cavity of the liner prior to filling.
 2. The shipping container of claim 1 wherein the walls of the liner further include a sidewall abutting region extending from the spout surrounding region and a base abutting region extending from the sidewall abutting region, the sidewall abutting region corresponding to the sidewalls of the rigid outer container and the base abutting region corresponding to the base of the rigid outer container.
 3. The shipping container of claim 1 wherein the spout further includes a base flange which is secured to the liner, the one way valve member includes a material flap which is attached to the spout by way of a weld, wherein a portion of the material flap is positionable in abutment with a lower surface of the base flange, to, in turn, seal the spout from egress of flowable material.
 4. The shipping container of claim 1 wherein the spout surrounding region is structurally configured for stretching between 5% and 15% in any direction.
 5. The shipping container of claim 1 wherein the spout surrounding region is substantially free of each of creases and folds upon the stretching thereof.
 6. A liner assembly for a shipping container, wherein the liner is positionable within an outer rigid container and fillable with a flowable material, comprising: a liner having a plurality of walls generally complementing the cavity of the rigid outer container, the liner defines an inner cavity, the walls of the liner include a spout surrounding region, a spout positioned such that the spout surrounding region extends thereabout, the spout providing fluid communication with the inner cavity of the liner, the spout including a one way valve which facilitates the ingress of flowable material while precluding the egress of material. whereupon filling of the liner with a flowable material, the spout surrounding region structurally configured for controllable stretching by the flowable material, to, in turn, facilitate flowable material in excess of a capacity of the cavity of the liner prior to filling.
 7. The shipping container of claim 6 wherein the spout further includes a base flange which is secured to the liner, the one way valve member includes a material flap which is attached to the spout by way of a weld, wherein a portion of the material flap is positionable in abutment with a lower surface of the base flange, to, in turn, seal the spout from egress of flowable material.
 8. The liner assembly of claim 6 wherein the spout surrounding region is structurally configured for stretching between 5% and 15% in any direction.
 9. The liner assembly of claim 6 wherein the spout surrounding region is substantially free of each of creases and folds upon the stretching thereof.
 10. The liner assembly of claim 6 further comprising means for controlling the stretching of at least one sub-region of the spout surrounding region.
 11. A method of filling a shipping container comprising: providing a rigid outer container; placing a flexible liner assembly within a cavity defined by the rigid outer container, the liner including walls defining a spout surrounding region and a spout; filling the flexible liner with a flowable material through the spout; and stretching the spout surrounding region with the flowable material during filling thereof by a flowable material.
 12. The method of claim 11 further comprising the step of precluding the egress of flowable material through the spout at least during the step of stretching the spout surrounding region.
 13. The method of claim 11 further comprising the step of precluding the stretching of any regions other than the spout surrounding region of the liner.
 14. The method of claim 11 wherein the step of stretching further comprises the step of stretching the spout surrounding region until the spout surrounding region is substantially free from creases and folds.
 15. The method of claim 11 wherein the step of stretching further comprises the step of stretching the spout surrounding region between 5% and 15% in at least one direction.
 16. The method of claim 13 wherein the step of stretching increases a volume of the liner by at least 5%. 